Clad beryllium-copper alloys



Sept 2 1952 v. G. MooRADlAN 2,608,753

CLAD BERYLLIUM-COPPER ALLoYs Filed May 24, 1947 @0l 0 0f? 077127? CL 40.0//1/6 KER FIG. 2

IN VEN TOR.

ATTORNEYS Patented Sept. 2, 1952 A-f--"2,608,753v v CLAD BERYLLIUM-COPPER. ALL'oYs* Victor G. Mooradian, East Orange, N.- J., assigner to The H. A. Wilson Company, Newark, N.AJ.,-v

a corporation of New Jersey Application May'24, 1947, S'erial No. 750,359 A I A 1 Y Y This inventionrelates tothe manufacture of clad beryllium-copper alloys, such, for example, as precious-metal-clad beryllium-copper alloys. The invention-is also applicable to the manufacture of a bimetal comprising a layer o f berylliumcopper. The terms bimetal and clad metal are to some extent used interchangeably in this application, although the term bimetal is generallyused in the trade to denote metal products composed of two layers of different `metal compositions but approximately equal thicknesses; whereas the term clad metal generally isused to denote composite metal products in which the surface layer, of one composition, is substantially thinner than the base layer of a diiferent composition, f f

Clad metals andbimetals generally'v are made b'y"s oldering, brazing or welding together sheets or-b'a'rs of the two or more different metalsof which the product is to be composed,` and rolling the resulting assembly vto the desired thickness. The manufacture of such conventional bimetals as brass-Invair thermostatic metal, and clad metals such as silver-clad or gold-clad copper and steel, presents no Yserious problems to-modern technology. Two or more `bars of the different metals, or a relatively thin sheet of one and a bar of the other, are usually brazed or silvers'oldered together by Well-known soldering or brazing procedures, and the resulting brazed or soldered assembly is then rolled to the desired thickness. Y f

The manufacture of -bimetal or` clad vmetal products having one layer composed of a beryllium-copper alloy has, on the other hand, proven very dicult.V In fact, it has not heretofore1 been possible to produce commercially, and with an economically low percentage of rejected material, a bimetal or clad metal product having a beryllium-copper alloy as a major constituent. The'V difficulty arises in part Afrom Y the nature ofthe heat treatment to'which itis desirable to subject the berylliumcopper Aalloy and the need for producing aY bondbetween the berylliumcopper and cladding metal that is exceptionally tenacious inv order to withstand the rigors of this heat treatment; and in part from the fact that the refractory beryllium oxide that' is valways present at the surface of aberyllium-copper alloy bar interferes with making even a moderately strong brazed or solder joint. Y

The chief advantage of the ordinary berylliumc0pper alloys is that they maybe annealed to a soft condition in which they may be worked 4readily byV mechanical means, and then may be 21 Claims. (Cl. 29--199) --through large temperature ranges.

precipitation-hardened by heat treatment to develop a high degree of mechanial strength Iand excellent spring properties. An'nealing of vthe alloy to render it soft enough for easy mechanical working generally involves heating the alloy at a temperature in the range from 1 2'75o F. to l475 F., fora period oftime long enough-for the beryllium to go into solid' -s olutionj in the copper, and then rapidly cooling; the alloy to near room temperature to hold the beryllium in solid solution. l AHardening of the annealed alloy -is effected by reheating at a; temperature from 500" F. to :700 F. for al considerable period of timeelong enough to permit the beryllium to percipitate from solid solution--and then-cooling. I

- It is evident from the foregoing' that to secure the advantages-obtainable by heat treatmentof the beryllium-copper-in aclad metal product having a layer of `this alloy, the bond between ,theA

beryllium-copper" and -the cladding metal must -hold firmly at 'the solution-an-nealr temperature (inthe range from 12'75o F. to1475 F. and for best results between l375 F. and 14'75" ZIEL),` and must withstand the severe strains imposed by the diiference 'in-the thermal expansion 'of r the different metals join'e'd thereby when the composite product lis heated land cooled rapidly Futher, the bond must withstand the'strains involved in severe mechanical working of the product. 4-The difficulty of Vproducing a bond that will hold firmly under these conditions iscomplicated by the :fact that the beryllium-copper alloy vmay not safely be'heated tc a temperature appreciably above. 1475o F. At higher temperatures-the alloy undergoes substantial grain v'growth that impairs its physical .properties and prevents securing the full advantages .of subsequent precipitationhardening; and it begins to melt at a little above .1500 F. f Hencefjoining of the beryllium-copper `to the cladding metal may notbe effected by a `solder that becomes molten only at temperatures l above the maximum heat treatment'temperaitures. rThe bond must be formed at a temperature not higher than 1475 F., but once formed it must withstand reheating'to the temperature at which it was formed, or even higher, without parting.v f i As a result of an extensive .investigation on this subject@ have discovered that a satisfactory bond maybe produced by the user-of asolderY (advantageously a silver r solder)V .having va flow` point below 1475 F. but above 1.100-n FQ and preferably above 1300J yif the solderingoperation is controlled so' 'asteeffect complete conversion of thesolder alloy, by Adiffusion with the adjacent aeoa'vea 3 metals, to an alloy having a melting point above its original flow point and above 1350" F., and advantageously even above 1500 F. The term flow point means the temperature at which the solder alloy is completely melted, whereas the term melting point means the temperature at which the alloy rst begins to become molten. In accordance with the invention, a film of the solder, with appropriate fluxes, is applied to a suitably prepared surface of a beryllium-copper alloy bar, and a sheet or bar of a cladding metal is also placed in contact with the silver solder. The assembly then is heated, under substantial pressure, to a temperature above the flow point y of the solder, and preferably above about 1400D F., in the range between 1300* F. and 1475 F., and is held at such temperature for a long enough period of time to effect complete conversion of the solder by diffusion with the adjacent metals to an alloy having a melting point substantially above its original flow pointv and above 1350" F., and advantageously above l500 F. In any event the alloy thus formed by diffusion must have a melting? pointv above the solution-anneal temperature of the beryllium-copper.

I have further discovered that proper preparation of the surface of the beryllium-copper bar is of great importance in order to produce a truly satisfactory clad beryllium-copper product. In l the rst place, the surface to which the silver Y or other solder is appliedV must be substantially oxide-free. Beryllium-oxidizes `extremely readily, and its oxide is highly refractory and is not slagged olf by any of the usual soldering fluxes. Moreover, itis important to prevent any metal which-forms a eutectic-w-ith beryllium having a melting point much below l500 F. from coming in direct contactwiththe beryllium-copper alloy. Gold, for example, for-ms a low-melting point eutectic with berylliurrrand-so must notY come in contact with the beryllium-copper` alloy'during the soldering operation or subsequently.v Otherwise incipient meltingmay occur at thev bond and weaken it- When the beryllium-copper is heated to its solution-anneal temperature.

Both of these needsare-met in accordance with the invention by electroplatingor otherwise applying to the surface of the beryllium-copper alloy bar a thin lm of av metal (a) whose oxides are readily iluxedv by ordinarysoldering fluxes, (b) which has aV melting point above 1350* F. and preferably upwards ofabout 1500 F., (c) through which beryllium doesnot readily diii'use, andv (d) the eutectic of which with both copper and beryllium has'a melting point above the solutionanneal temperatureof the beryllium-copper alloy. The rst two'of these requirements are of importance generally; and' the last two in special cases. Copper and'nickel are'metals that meet all these requirements, andaccordingly a thin lmof copper or nickel may be electroplated or otherwise applied to the' beryllium-copper alloy bar to form the surface to which the cladding metal is soldered.- Silver, copper alloys such as brass, and nickel alloys such as cupronickel, may also be employed for this purpose.

Gold-clad beryllium-copper is a particularly advantageous productY of the invention.r Goldcladding imparts to the product the color and appearance much in demandA for jewelry and allied products, while-the beryllium-copper may by heat treatmentV be vgiven high strength and excellent spring properties not available in ordinary jewelry metals. However, gold alloys of the character ordinarilyv employed in the jewelry trade are likely to undergo rcrystallization and substantial grain growth when heated to the high temperatures involved in the heat treatment of beryllium copper. Such grain growth imparts an objectionable crystalline appearance and even a rough surface to the completed article-a defect commonly known as an orange peel effect. This defect may be overcome by employing a gold-cladding layer containing from 0.5% to 3% of nickel or cobalt, or both. Accordingly, the invention contemplates, in the manufacture of gold-clad beryllium-copper, the use of a goldcladding alloy containing nickel or cobalt, or both, in an amount within the above-stated range.

The manufacture of a rolled composite strip of gold-clad beryllium-copper is described below by Way of example to illustrate the invention. In the course of the description, reference is made to some of the modications that may be made in the procedure specifically described; and novel features of the invention not'l particularly mentioned above are set forth. It is understood that the invention is not confined to the example specifically described, and that the novel features mentioned below are as much a part of the invention as are those briefly described above.

A suitable bar of beryllium-copper alloy is first treated to prepare its surface for bonding to a gold alloy cladding layer. A bar of the character known to the trade as a "platers bar is generally most satisfactory. Such a bar is usually about an inch thick, perhaps five inches wide, and about ten to eighteen inches long. The bar should, of course, be of a composition that may be precipitation hardened by the usual berylliumcopper heat treatment. The normal composition of the` ordinary commercial beryllium-copper alloys is 2% to 2.25% beryllium, 0.5% max. nickel, 0.25% max. iron, and the balance copper. The beryllium may, however, range from 1% to about 3%, and minor quantities of otherv metals Vthan those mentioned may be present.

. The bar will usually be received from the metal supplier in the solution-annealed condition (that is, it vhas been heated to a temperature in the range from 1275 F. to 147 5 F. and rapidly cooled to render it workable). The exposed surfaces of solution-annealed beryllium-copper are usually more or less oxidized, and oxidation products penetrate the grain boundaries to an appreciable depth below the surface. The first step is to remove these surface and intergranular deterioration products. This is best-` accomplished by mechanically cutting a surface layer of metal from the bar. The depth of cut shouldbe sulficient to remove not only the visible surface oxides, but also such' oxidation products as may penetrate the grain boundaries near the surface.

lthin film of nickel or copper on the cutsurface.

ItVr is imperative that the electroplated nlm. adhere tenaciously to the beryllium-copper, and this in turn necessitates a scrupulously clean surface onk the bar. A' particularly satisfactory procedure for cleaning the bar immediately prior toplating involves first. washing the bar in an alkaline cleaning and degreasing solution,'and

then washing in dilute hydrochloric acid, followed by-risingr in water. The cut surface ofthe bar is then scrubbed with pumice or other mild abrasive until no water-breaks form on it. By this `I mean that when a film Vof clean water covers the scrubbed surface, it remains continuous and does notV break up into globules of the character seen whenI a small amount of water isl used to wet a greasy surface.

In some instances it is -possible to dispense with one or more of the cleaning steps mentioned above. For example, it is occasionally possible to produce satisfactorily clean surfaces an adequately clean surface. Generally it is best,

however, to use the complete cleaning procedure outlined above. The mild abrasive action of pumice or the like during the course of the scrubbing operation roughens the surface lightly and improves the adherence of the subsequently applied electroplate. Y

Hydrochloric is the most satisfactory acid-to employ Vin the above-described sequence ofcleaning operations, although other acids maybe-employed. However, strongly oxidizing-acids, such as nitric, should be avoided. The bar should not remain in the acid solution long enough for any substantial amount ofmetal to be dissolved, for the hydrogen then liberated is likely to penetrate into lthe metal and lead to a non-adhering electroplate.

In any event, after completion of the nal step in the sequence of cleaning operations, the bar is kept wet with water until the plating'bath is ready to receive it. I have found thatif the bar, after cleaning, stands dry in the air for even ashort while, enough oxide, dirt or similarly behaving contaminant collects onY the surface to on the other hand, deleterious contaminants do not accumulate very rapidly; but even when the bar is kept wet, it is inadvisable to defer plating for more than a few hours after completion of? the cleaning operations.

-Plain, clean water is the most. convenient medium with which to keep the cleaned surface of the bar wet between the cleaning. and plating operation, but it is also possible to use a suitable water solution for this purpose. Thus, quite dilute hydrochloric acid solutions have been used with success. I

The next step is to electroplate on the cleaned cut surface of the bar a thin lm of copper, nickel or other metal or alloy having an easily .tuxed oxide and an adequately high melting point (preferably above 1500 FJ. The electroplated lm is applied by the usual electroplating techniques.

In the case of a copper electroplate applied from an acid electrolyte, it is particularly advantageous to subject the barinitially 'to twenty to twenty-five amperes per square foot. Alternative to operating initially at a low current density in an acid electrolyte, a flash 'Y deposit of copper may be applied by electrolysis Y:in a cyanideplating bath, after which the copper electroplate may be built up to final thickness irl an acid bath at a fairly high current density.V If a nickel velectroplate is appliedrin place'of copper, using an acid electrolyte, it is advantageous to follow-substantially thesame procedure described above, that is, to operate initially at a low current density and to raise the current density to the final value only after an initial thin deposit has been formed on the bar.

Initial operation at low current density,.or, in the case of copper, initial applicationof a flash electroplateffroma cyanide plating bath, produces a much more adherent .deposit on beryllium-copper than can be obtained if.A the plating operation commences; at a highV current density. A Whilecopper and nickel are specically mentioned as the metals composing the film applied to the prepared surfaceof the beryllium-copper bar, andwhile these are in fact thepreferred metals to employ, itis possible to usel some other metal instead, as indicated above. For example, an electroplate of silver may sometimes be substituted for the copper or nickel film. Electroplates of brass, bronze and copper-nickel alloys may also :be applied.

Application of the copper, nickeLor other metal film by electroplating is generally preferred because it does not require any particularly elaborate apparatus and has been found togive very .satisfactory results, but othermethods of appli- .cation are feasible.A For example, a thin film of the chosen metal may be applied by sputtering or evaporation in vacuum. c

The bar withits. electroplated film of. copper or other metal is prepared for application of the cladding metal by -grinding orsanding the electroplate on the cut surface of the bar. This grinding or sanding operation serves several purposes. It insures a fiat but lightly roughened surface that iseminently satisfactory to receive the solder. If, asis bes-t, the sanding or grindingis. performed just prior to soldering metal in place, it serves to remove the dirt and oxides that will have accumulated on the bar if any substantial time has elapsed since completion of the electroplating operation. Finally, it serves to reduce the thickness of. the copper `or other electroplate to the optimum value. A film atleast about 0.0005 inch in .thickness should remain'on the bar after sanding,.but the thickness should not exceed about 0.004 or 0.005 inch. .A film Whose thickness-is in the lower part of this range is generally sufcient to prevent the gold ofthe cladding layer from diffusing into contact with the beryllium of the beryllium-copper alloy and forming localized cores of low-melting eutectic, which would impair the quality of the bond between the beryllium-copper and the gold cladding. metal. On the other hand, a copper or other lm thickness greater than about 0.005 inch is likely to lead to a weakened bond, because the electrodeposited metal has rather low physical strength.

The bar, after sanding or grinding the electroplate on its cut surface, is ready for being vsoldered to a sheet of gold alloy or other cladding metal. This operation is best carried out as follows: The prepared surface of the bar is coated with a suitable iiux, such, for example, as a hot solution of boric acid. A thin sheet of silver (or other metal) solder, also advantageously flux-coated, is laid over the surface of the bar, and a flux-coated sheet of gold alloy is then laid over the sheet vv-of silver solder, thus forming a sandwich of the silver solder between the beryllium-copper bar andthe gold. v 1' The solder should be one having .an initial melting point and a flow point between 1100g F. and 1450 F., and preferably it should have its initial .melting point and flow point between 1300o F. to 145()D F. In addition, .it must be. able tofdiffuse readily at the soldering temperature with one or both of the adjacent metals, so as vto form therewith an alloy having a melting point above 1350Q F. and advantageously .upwards .of 1450 F. or even 1500g F. Since silver and silver alloys difiusereaclilyv with the usual :karat-.gold alloys, and form .adequately high-melting alloys, such solders are preferred for usein mak-v` ing gold-clad beryllium-copper. The diffusion alloyformed by the solder Awith the adjacent metals must be suciently `ductile to be worked exten sively and to withstand the strains imposed .upon

it by diierences in the work-hardening characteristics and the different vthermal co-eiiicients of expansion of the metals which it unites. The properties of many silver .solder alloys meet all of these requirements Very well, provided they do not contain a high percentage of such low-:melt- A ing point metals as zinc, tin .and antimony. A silver solder that has been used successfully is composed of 64% silver, 30% copper, 5% .zinc and. 1% tin. This solder has an initial melting point at about 1340 Rand a ilow point `at about 1425n F. The percentage of tin and zinc which it contains is not high enough to be detrimental. Another solder that can be used with..advantage is the eutectic alloy of copper Vand silver, composed of about,28% copper and the balance silver.: This alloy melts sharply atabout 1430" F. Other silver solders having the .required Ymelting characteristics andthe required .physical properties are available and may be used.

It is .advantageous .to sand the sheet of silver solderV just .before Yit issandwiched between the lberyllium-copper and .gold layers. In this way `surface rdirt and oxides that would interfere with `obtaining a vgoodsoldered joint are for the ,most

part removed. The sheet `of silver solder .used -need not,vand `preferably should not be very thick. Asolder sheet about .003 inch in .thick- -ness is generally satisfactory, although it 4may be somewhat thinner or thicker.

The gold alloy used '.for .cladding .should be -of such composition thatit will not ybe deleteriously affected by the. high temperature to .which it is subjected during vsolderingand subsequently .during heat treatment of :the beryllium-copper.

.In thecase of gold-,clad beryllium-copperalloys prepared .to have an ornamental .gold surface, i-t isv desirable to employ analloywhich does not Wundergo coarse grain growth when heatedpto 4the Asoldering orsolutioneanneal temperatures. Many karat-gold alloys upon :being heatedto or above their respective recr-ystallization temperatures (which .usually are well below the .solution-anneal temperature of beryllium-copper) .undergo coarse grain growth, but gold alloys containing A6.5% to 3% of nickel or .cobaltasagrain growth f,

8 yellow gold alloy is composed of about 581.3% gold, 25 to 30% copper, 8 to 1,2% silver, 2 to 10% zinc, and 1/2 to 3% of nickel or cobalt, or both.

It is desirable in some cases to use a precipitation hardenable gold alloy as the cladding metal. By using an alloy of this character that becomes hardened when subjected to the same heat treat-V ment procedure as employed for hardening the beryllium-copper, it is possible to produce a goldcladl product on which the gold-cladding layer is particularly well able to resist wear dueto f requent handling. Typical precipitation .hardenable gold alloy compositions suitable for use as the cladding layer are set forth in the following table:

1SKarat ll-Karat l1Karat lei-Karat White Yellow Yellow- Gold l y del@ Green Gold @een Gold Percent Perce-nt Percent Percent 75 '58. ,3 58. 3 5S. 3 11. 0 20. 85 30. 2e. 4 2o, e5 v6.o 2. 0 l. 5 2. e .4. e

The foregoing alloys become solution-annealed at about the same temperature employed for solution-annealing beryllium-copper 1275 to 1475" FJ, and'precipitation harden at about the same reheatingtemperature at which berylliumcopper precipitation hardens (500 F. to '700 El. Hence a single heat treatment suices to harden both the kgold alloy and the beryllium-copper :of a Glad metal product on vwhich these alloys are used as the cladding layer. If the gold-cladding alloy is of such composition that it requires somewhat different solution-anneal and -reheating temperatures than the beryllium-copper. .it is often possible to compromise the heat treatment procedure, using temperatures that are .not optimum for either the beryllium-.copper orthe gold alloy, but that .impart useful and .adequate hardening to both constituents of the .clad product.

YThe .particular gold .alloys ,set .forth :above are mentioned only by wav .0i example. Other .gOld alloys may also be :employed in making the new clad product.

As in the case of the silver solder andthe elec troplated beryllium-copper, itis advantageous to sand or grind the vsurface of -the gold Aalloy .sheet just .before making it into thesandwich. in order to' remove such surface ,dirt and other ...contaminants as would "be likely to impair the quality of .the soldered zbond.

After the sandwich of berylliumfcopper, silver solder, and gold has been prepared, a layer of .asbestos paper orother refractory material hav- 'ing low-.heat .conductivity is applied over the gold. The amountof asbestos paper used depends on the thickness of the gold alloy and .on the melting point of the solder, as its purpose is .to prevent, during soldering, having vthe solder heated to its melting point by .heat .conducted through the gold before theentire mass of the beryllium-copper bar has :been `brought to the .soldering temperature.

The sandwich, now ready :for the solderingv operation itself.. 'is compressed :between .steel :plates and heated V.to the vsoldering .temperature .One `conventienal platers furnace technique for soldering involves Vclam-ping the sandwich `between backing plates of steel by Vmeans of .heavy clamps, placing-the assembly ,ina furnace, and heating `to 4,the proper temperature. While.this

heated along with the sandwich; kIn the second place, elimination of the clamps that are necessary to hold the sandwich between the backing plates in the clamp-type platers furnace enables the sandwich to be heated uniformly to the soldering temperature. When clamps are employed for holding the assembly together in the furnace, they must be quite heavy, and because of their mass they cause the sandwich to be heated more slowly in the regions of theclamps than in the regions between clamps. Such uneven heating is disadvantageous because the parts of the sandwich that are heated more rapidly may became overheated before the more slowly heated sections reach the flow point of the solder. As indicated above, overheating of the beryllium-copperv must be avoided.

The sandwich between massive uniformly preheated platens is quite rapidly brought to the flow point of the solder, largely by heat conducted from the platens through the gold and through the beryllium-copper bar. It is important that the Ventire mass of the beryllium-copper bar be heated uniformly to a temperature in the range from 1275 F. to l475-F. and preferably in the range from 1375 F. to 14'75" F. during soldering, so that it will be in the solution-annealed condition at the completion of the soldering operation. The asbestos paper or equivalent heat insulation layer) laid over the gold layer before introduction of the sandwich into the furnace, and whichretards the rate of heat flow from'one platen through the gold to the solder alloy, servesthe Y The vasbestos paper (or equivalent heat insula-v tion) should not be so thick that thegold layer is prevented fro-m reaching the soldering temperature until substantially after the berylliumcopper has done so. Too-thick asbestos may result in overheating the beryllium-copper before adequate diffusion of the solder alloy with-the adjacent metal has occurred. The ideal asbestos thickness is that which enables the gold alloy adjacent the solder to Lreach the soldering anddiffusion temperature at just about theV same time that the beryllium-copper near the solder reaches this temperature.

The sandwich is held between the platens in the furnace for a sufficient period of time after the solder has melted to insure heating the entire mass of beryllium-copper to between 1300 F. and 1475 F., and to permit the solder to inter'- diffuse with the adjacent gold layer andthe electroplated copper film and form therewith analloy having a melting temperature above 1350 F.

and preferably upwards of 1500 F. The amount of time required for this diffusion to occur is not long if the initial melting point of the silver solder is above 1300 F. and the cladding metal is gold. In this case a ydiffusion time of the order of one or two minutes after the solder has reached its flow point is usually suicient. If the initial melting temperature of the solder is much below 1300 F., however, or if the solder does not diffuse readily with the adjacent metal, a somewhat `longer diffusion time may have tobe allowed.

yBeryllium and gold form a eutectic having a melting temperature in the general neighborhood `of 1000" F., and if these two constituents of the clad metal product dilfuse into contact during soldering or during subsequent heat treatment, small cores of this low-melting eutectic may develop .and weaken the bond between the cladding layer and the base metal. Accordingly, a thin lm of the copper or other electroplate, unmodiedf bydiffusion, should remain between the cladding layer and the beryllium-copper alloy,y

initial thickness of the electroplate and the diffusioncharacteristics of the metals employed so that there. will be no substantial areas where the diffusion has modified the composition of the electroplate throughout its entire thickness. The use of asbest-os paper, as described above, is helpful inpreventing such an occurrence during the soldering operation when the cladding layer is thin lcompared to the beryllium-copper bar.

. ,During the entire coursevof the soldering operation, the sandwich is kept under considerable .pressure between the heated platens. After the solder has melted, the excess oozes out as a bead around the edges of the bar. The first appearance of this bead, indicating that the solder has reached its flow point, may be taken as a referencev point in time for judging the length of the time interval to be allowed for the proper amount of diffusion totake place.

Upon completion of the soldering operation, the lberyllium-copper bar has been uniformly heated to `vits solution-annealing temperature between 1300 F. and 1475 F. To hold the beryllium in solid solution, the bar should be rapidly cooled, and cooling should be effected so asvnot to injure the .freshly formed soldered joint. The most satisfactory way in which to effect this rapid cooling is to transfer the sandwich, upon completion of the soldering operation, from between the heated furnace platens to between a pair of massive relatively cold metal plates, and to compressA it therebetween. The sandwich cools rapidlyvunder these conditions by conduction of heat to the cold platens, which are massive enough to absorb a large quantity of heat from the soldered assembly. Since the sandwich is vcompressed between the cold platens during this period of cooling, the soldered joint remains intact.

It is not necessary that the soldered assembly be cooled all the way to room temperature while compressed between the cold platens. It is sufficient if the assembly is held between the platens yor 145e F.

11 only until it has reached a. temperature inthe range'from 700 F. to 1000Cl F.' The assembly then may be taken from between thefcooling` platens and may be quenched to room temperature in water 'or other suitable medium. In fact, it is advantageous to conduct the cooling in this fashion, because there is then minimum opportunity for any of the beryllium in solid solutionto precipitate and cause hardening of the berylliumcopper alloy. Initial cooling between the platens proceeds quite rapidly, but' iinal cooling from about 800 F. to room temperature proceeds more and more slowly. Since the precipitationhardening 'temperature for the beryllium-copper alloy is generally between 500 F. and 700 F., it is advantageous to conduct the cooling in the two steps described above, so that the berylliumcopper will not remain 'at a temperature between 500 F. and 700 F. any longer than is necessary.

When the soldered assembly has been cooled to room temperature, it is ready for reduction to final thickness by rolling. Before rolling, it may be advantageous to pickle the assembly in acid, to remove the bulk of the oxides that have formed on the exposed surface of the beryllium-copper during soldering and during the initial cooling in air between cold platens. buch pickling, however, is not always necessary.

Rolling the bar to final thickness is carried out in the usual manner. The bar generally may be reduced 50% or more in thickness before the beryllium-copper has work-hardened to the point that it must be annealed before being rolled further. Such annealing is conduct-ed' in the usual manner for beryllium-copper. It may in each case be effected by heating-,the bar to the solution-anneal temperature between l375 F. and 1475" F., and then quenching to room temperature.y An alternative' annealing procedure :involving heating to a temperature of about 900 F. to 1050 F. fora period of several hours is sometimes preferable. This alternative annealing procedure (essentially an over-aging treatment), since it does notf'require heating to so high a teniperature, may be carried out with minimum danger of weakening the soldered joint between the beryllium-copper and the cladding layer of gold alloy. However, after a series of rolling operations and intermediate anneals have brought the bar to its final thickness, it is necessary to perform a final soluticn-anneal by heating to 1275 F. to 1475" F, (preferably 1375u F. to 1475 F.) and quenching. This is because the metal in the over-aged condition cannot be precipitation hardened; it must be solution-annealed before it will respond to precipitation-hardening treatment. l

Fig. 1 of the drawings illustrates diagrammatically iny cross section, on a scale that has been distorted for purposes of clarity, a clad berryllium-copper product prepared as described above. i

The exemplary procedure described above for making gold-clad beryllium-copper involves applying the gold-cladding layer directly to the copperor other metal-plated beryllium-copper bar. An alternative procedure that may be employed with success involves first making a master plate of gold and a base metal (interliner) such as copper, nickel, brass, or the like. Such a master plate may be made in accordance with Wellknown cladding procedures by soldering a sheet of gold to a sheet or say copper, preferably using a silver solder having a melting point upwards In any event, the solder, and the lrial for the jewelry and allied trades.

tricate shapes,

other constituentsiof the master plate as well, should have a melting point above 1350 F. The master plate usually is made quite thick, with approximately equal thicknesses of gold and base metal (say with 1/4 inch gold and 1A, inch base metal). It is then reduced by rolling to the desired thickness (say Te inch) for cladding `purposes. berylliumcopper bar, following substantially vthe procedure described above. While this method of making the clad product involves the extra step of rstimaking the Vmaster plate, it has the advantage that` a relatively thick' layer of coppercr other base metal interliner separates the'gold from the beryllium copper, and minimizes anyr possibility that cores of low melting gold-beryllium'eutectic will be formed during soldering, or subsequently during annealing. Since the interliner has the good physical properties of rolled metal, it may be much thicker than electroplate on the beryllium-copper bar Without reducing the strength of the product at the bond. 'A clad metal product prepared in accordance with this alternative procedure is shown diagrammati'cally in Fig. 2.

Still another procedure that can be followed, and that leads to a product similar to that prepared using a master plate, is carried out as follows: A sandwich is prepared by applyinga sheet of solder having a flow point between 1100xv F. and 1450" F. to the prepared surface of the beryllium-copper bar, then applying a layer of copper, nickel, silver, brass or other metal as an interliner (the interliner should have a melting point above 1350o FJ, applying over this layer a second sheet of solder (which, like the first solder layer, should have a melting point between ll00 F. and 1450" FJ, and Afinally applying the layer of gold or other cladding metal. The thus prepared sandwich is then subjected to the soldering procedure described above (at a temperature between i275c F. and 1475 F. that is above the flow point of both'solders but below the melting point of any other constituent of the sandwich) to unite the gold to the interliner and theV interliner to the beryllium-copper. The soldering operation is so conducted that both solder layers form, by diffusion with the adjacent metal, alloys having melting points above the original iioW points of the solders and above 1350 F., and advantageously above 1500` F., rso that the resulting product may subsequently be heated to the solution-anneau temperature of the beryllium-copper Without weakening the soldered bond. This product also is of the character shown in Fig, 2.

Rolled strip of gold-clad beryllium-copper prepared as described above is a highly useful mate- The gold cladding presents the attractive appearance that is much sought in articles for personal adorn*- ment and kindred items. The strip in the solutionfannealed condition is easily worked into inand after. Working, mayk be hardened greatly and given valuable spring properties by reheating for several hours at 500 F. to 700 F. and then cooling.

While numerous articles may be made from gold-clad beryllium-copper strip, one such product that may be mentioned specifically by Way of example is the pocket clip with which pencils and fountain pens are usually provided. The manufacture of such clips involves severe Working of the metal, and the nished product must possess goed spring properties. Ieretofore it has been rPhe rolled master plate is soldered to a necessary to make such clips fromvhard-r'olled gold-clad phosphor bronzeV or similar strip. A

may be given satisfactory spring properties. The I hard-rolled material, however, is diflicult to fabricate into even relatively simple shapes, and the severe working that is necessary, yfor example, to form a ball-end on the clip can be accomplished only after very painstaking spot-annealing of the metal, conductednso as not to anneal that part of the clip whichmust be springy. e

With gold-clad beryllium-copper prepared as herein described, the clip is easily fabricated while the metal is in the soft solution-annealed condition. Thereafter it'may be precipitation-hardened in the manner described to impart spring properties even superior to what may be attained in Work-hardened Phosphor bronzes and similar metals.

While the invention has been described specically with reference to the manufacture of a rolled strip of gold-clad beryllium-copper, the features of the invention are equally applicable to making other clad beryllium-copper products.l

For example, it is not essential that the cladding metal be gold. Other precious metals, suchf'as silver and platinum, and base metals,lsuch as copper, nickel, iron alloys, etc., may be applied as the cladding metal to, or as the second layer of a bimetal with, beryllium-copper alloy. Sil- `ver-clad beryllium-copper, for example, may be made substantially as herein described, 'simply-by substituting Va silver or silver alloy cladding-layer for gold. A copper-clad beryllium-copper alloyA ment. Bimetals of soft iron or an iron alloy with beryllium-copper alloy have utility, for example, Where a combination of magnetic. and 'spring .properties are desired, as in armatures for certain types of electrical relays. Berylliu'm-.copper Vclad with nickel or nickel silver (an alloy of copper, zinc and nickel) in accordance with the' invention has proved to be Ya valuable material for many industrial uses. i

Other shapes than the singly-clad rolled strip specifically described above may be made in accordance with the invention. Such products as those known to the trade as edgelay, inlay and centerlay composite metals, having a zberylliumcopper alloy component, may be made in accord- T121 beryllium-copper core in connection vwith thev appearance of a gold-cladding layer, the electrical conductivity of a silver 'or copper cladding layer,

easily uxedsandwiching a solder having a'ilow point between 1100 F. and 14:50"v F. between said coating and a layer of cladding metal, andsublstantially uniformly heating the sandwichfat va temperature above the'iiow point ofthe solder, but'b'elow 1475 F., and under substantial pressure for a sufficient period of time to-aiect lc'omplete conversion of the solder by diffusion-with the adjacent metals to an alloy having a melting temperature substantially above the initial flow pointof the solder and above about 1350 F., the duration of the heating *being such that there is no substantialarea wherediiusionhas-"niodified the composition of the coating metal throughout its entire thickness. v

2. The method ofgmanufacturing clad"be ryl lium-copper'as setrf'orth in claim i1 in whichthe coating is ametal from the group consistingfof copper and nickel and the' alloy obtained lby conversion of thev solder with adjacentfmetal's'fhas a melting point above about 1500fF af'rhe methodb'f" manufacturing ciad biery1- l lium-copperas setforth vinclaim 1A vwhich.'the

ance with the invention substantially as described above. Beryllium-copper having an edgelayof silver, forexample, isV particularly useful for fabricating electrical spring contact elements.

It is also possible, in accordance with the invention, to apply a cladding layer of gold or other metal to a round rod of beryllium-copper, which may be drawn into the form of gold-clad beryllium-copper alloy wire; and similarly wires having a beryllium-copper core and some other cladding layer than gold may be prepared. Such wires may be used for manufacturing springs and similar articles requiring the physical properties that may be developed by heat treatment of theA depositedon the`'Joeryllium-coppen4 v8. The method ofy manufacturing--clad-"berylf vlium-copper as set forth in claim 1 'iri-whichtl'fie vsolder is a silver solder.

4. The method or manufacturing yciad idcffyi:r 7 hum-copper asset forth 'inA claim 1in-which thef cladding metal is a gold alloy'inhibited against coarse-grain growthfat temperatures up to l .1,50()F.` f f 1 51V The method ofY manufacturing clad 'beryle 1 hump-'copper as set forthin claim lin whichthe i cladding metal is a gold alloy containing-'from 0.5% vto 3%"of a metal selectedfffrom'thgroup consisting of nickel and-'cobalt and is inhibited against coarse-grain growth at temperatursfup f liurn-copper as'set forth inA claim 1 in which the "coating is less than0.005 inch thick andis electrol surface of the beryllium-'copper fonto vvfhich` the coating is applied is preliminarily treatedlto'form a fresh sur-face by removing therefrom suiiicint metal to :remove surface oxides and vsuchi'nltergranular deterioration produ'ctsas arenormally present` near the surfaceof 'annealed 'beryllium- 9. The method' of manufacturing"clad=beryllium-copperas set forth in claim llfinfwhicli, during .the heating, the sandwich is 'pressed between relatively-massive, uniformly-heated` platens..

. V10; Thecmethod of manufacturing clad 'beryl- K lium-copper` as set forth'invr claim 1 in whichma- '15 tween;relativelyemassive, uniformlyheated platens :which are pressed against it.

.111. The method of manufacturing clad beryllium-copper as set forth in claim 1 in which the clad beryllium-copper is rapidly cooled by insert- --ng it, while still hot, between a rpair of relatively-massive Aand relatively-cold 4metal platens 1and,compressing the cladberyllium-cooper therebetween until it Vhas cooled toa temperature of from 700 :to i1000 kand inwhich the clad beryllium-cooper is thenremoved from between :the gplatens-and quenched Yto near'room temperzature. Y y

'12. The method of manufacturing cladberylhum-cooper aslsetforth in claim 1 in whichthe lcoating .s: anelectrodeposited one less than about :0.005-inchv thick of a metal from the class-consisting-of cooper and nickel, the electrodeposited .coating is ground to a flat surface and lthesclad- .ding metal is a precious one. s

13. The -methodfofV-gold cladding beryllium- ,copper whichcomprises preparing a relatively- -thick masterplate -by soldering a layer `of gold `alloy to a vbase interliner metal (a) through which beryllium does not f readily, difiusa (b) the-.eutectic of which with beryllium ha's'a melting point.. above 1350o F.,V and f(c) the oxide-of which is easily uxed, the soldenfgold alloy and .,interliner metal vall having -rneltingnpoints above 1-350" rolling theresulting masterplate to a desired thickness, sandwiching a second solder ,having a fiowpoint'between 1100 F. and 1400" F.

between-the -interliner-.face of the rolled vmasterplate and a substantially oxide-free surf-ace of rabar of beryllium-copper, and heating the sand- .wich while-.under substantial pressure at a temperature above the ow point of -said vsecond .solder Abut belowthe-melting temperature of any vcomponent-or the `masterplate and below about MHT-F. `for a suflicient periodi of time -to -aiect completeconversion of said second solder .by diffusion with adjacent metals to an alloy'having a melting temperature substantially above its `original now-point vand -above 1350 F., the heat- -ing being such that there is no substantial area -Where diffusion has modified the composition of nthe base interliner kmetal throughout its entire `area. Y

14. The method of manufacturing gold clad beryllium-copper which comprises preparing a I v.sandwich comprising a bar of :beryllium-copper having a substantially-cXide-freesurface, a sheet of solder having a flow point between 1100 and 14:00o F., va base interliner -meta-l (a) having a sucient period of time to convert the solder bydiiusion with adjacent metal to alloys having melting temperatures substantially above their foriginal iiow points and above 1350 F'.,-the heating being such Y.that there iis no substantial area :wherevdiiiusion has modied the composition of Vthe base interliner metal throughout its entire "area" :15. .Solution-.annealable composite metal stock comprising` a ibase .of beryllium-copper, =a` layer o'f .aninterliner metal -having one face bondedto the beryllium- Vcopper ybase, said interliner metal being one (a) vhaving 4a melting point `above 13505121., (b) through which beryllium does not 'readily idiiuse, (c) the eutectic of which `with Vberyllium vhas a melting point above 1350?F.,

Vand. (d) ithe voxide of which iseasily fluxedfand a layer of cladding metal secured to rthe Opposite 'face of 'the Vlayer of interliner metal, lthe interfacial portions only of the interliner metal and the 'cladding metal having interdiffused therein the metal components of fa silver solder having a ow point between 1100 F. and 1450" F. and

`forming therewith interfacial alloys having a .melting point `above the solution-anneal temperature of the beryllium-coppen whereby a `portion of the interliner metal unmodified by diffusion separates the cladding Y,metal from the berylliumcopper base. I

16. Solution-annealable composite metalstock .comprising a base of beryllium-copper, ,a `layer `Voff'an -interliner metal having one face bonded .to tlieberyllium-copperbasa'said interliner-metal being one ...(a) havingr a melting point `above -13 50 ib) through which beryllium does 'not `readily diffuse, (c) the entectic of which with beryllium has a melting point above 1350or F., and .(d) the Voxideof which is easily uxed, and a 'layerof cladding metal secured tothe opposite face of the layer of `interliner metal, the interfacial portions only of the interliner metal and the cladding metal having -interdiffused therein the metal components of ra silver solder having a-flow 'point between 1100o F. andA 1450l F. ,and

forming `therewith interfacial alloys having ia melting point ,above kabout A1350o whereby a portion of the interliner ,metal unmodied by diffusion separates the cladding-metal `from fthe beryllium-copper base.

1'7. Composite metal stock as setforth in claim 16in which the cladding metal is a gold alloy.

1.8,. Composite metal stock assetforthin .claim 16 'in which the Acladding metal rstock: Ais a gold alloy containing ffrom about 0.5% Yto '3% of 4a metal selectedjfrom the group consisting of nickel and cobalt.

' 19. Composite metal stoel: as setforth inclaim 16 in which the interliner metal is a metalfrom thegroup consisting of copper and nickel.

20. Solution-annealable composite metal stock Vcomprising in the order named a base of beryllium-copper, a layer of a metal (a) having a melting point above 1350 F., (b) through which beryllium does not readily diffuse, (c) vthe eutectic of which with beryllium has Ya Vmelting V'point above 1350 F., and (d) the oxide of vwhich is easily 'luxed ra layer kof an alloy of said metal with Vthe metal components of a .silver solder having a flow point between 1100 F. and 1450" F.,

a layer of a gold alloy containing the lmetal components of the same silver solder,.and a layer of the same goldalloy without the components vof the silver solder, the layers of the alloys containing'the vcomponents of the silver solderlhaving a melting point above the solution-anneal temperature of the beryllium-copper, said layers Aand the base being bonded together.

21. Composite metal stock as set forth in'claim .16 in which the vcladdingmetal is a precipitation- 'hardenable .gold alloy. r

VICTOR MOORADIAN.' i

(References on vfollowing page.)

1 7 REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date Kammerer Apr. 18, 1933 Pryde May 22, 1934 Davgnon Dec. 17, 1935 Wasson Dec. 6, 1938 Peterson Nov. 26, 1940 Weaver Mar. 4, 1941 Number 10 Number E 

1. THE METHOD OF MANUFACTURING CLAD BERYLLIUM-COPPER WHICH COMPRISES APPLYING TO A SUBSTANTIALLY OXIDE-FREE SURFACE OF A BAR OF BERYLLIUM-COPPER A COATING OF A METAL (A) HAVING A MELTING POINT ABOVE 1350* F., (B) THROUGH WHICH BERYLLIUM DOES NOT READILY DIFFUSE, (C) THE EUTECTIC OF WHICH WITH BERYLLIUM HAS A MELTING POINT ABOVE 1350* F., AND (D) THE OXIDE OF WHICH IS EASILY FLUXED, SANDWICHINGG SOLDER HAVING A FLOW POINT BETWEEN 1100* F. AND 1450* F. BETWEEN SAID COATING AND A LAYER OF CLADDING METAL, AND SUBSTANTIALLY UNIFORMLY HEATING THE SANDWICH AT A TEMPERATURE ABOVE THE FLOW POINT OF THE SOLDER, BUT BELOW 1475* F., AND UNDER SUBSTANTIAL PRESSURE FOR A SUFFICIENT PERIOD OF TIME TO EFFECT COMPLETE CONVERSION OF THE SOLDER BY DIFFUSION WITH THE ADJACENT METALS TO AN ALLOY HAVING A MELTING TEMPERATURE SUBSTANTIALLY ABOVE THE INITIAL FLOW POINT OF THE SOLDER AND ABOVE ABOUT 1350* F., THE DURATION OF THE HEATING BEING SUCH THAT THERE IS NO SUBSTANTIAL AREA WHERE DIFFUSION HAS MODIFIED THE COMPOSITION OF THE COATING METAL THROUGHOUT ITS ENTIRE THICKNESS.
 15. SOLUTION-ANNEABLE COMPOSITE METAL STOCK COMPRISING A BASE OF BERYLLIUM-COOPER, A LAYER OF AN INTERLINER METAL HAVING ONE FACE BONDED TO THE BERYLLIUM-COPPER BASE, SAID INTERLINER METAL BEING ONE (A) HAVING A MELTING POINT ABOVE 1350* F. (B) THROUGH WHICH BERYLLIUM DOES NOT READILY DIFFUSE, (C) THE EUTECTIC OF WHICH WITH BERYLLIUM HAS A MELTING POINT ABOVE 1350* F., AND (D) THE OXIDE OF WHICH IS EASILY FLUXED, AND A LAYER OF CLADDING METAL SECURED TO THE OPPOSITE FACE OF THE LAYER OF INTERLINER METAL, THE INTERFACIAL PORTIONS ONLY OF THE INTERLINER METAL AND THE CLADDING METAL HAVING INTERDIFFUSED THEREIN THE METAL COMPONENTS OF A SILVER SOLDER HAVING A FLOW POINT BETWEEN 1100* F. AND 1450* F. AND FORMING THEREWITH INTERFACIAL ALLOYS HAVING A MELTING POINT ABOVE THE SOLUTION-ANNEAL TEMPERATURE OF THE BERRYLIUM-COPPER, WHEREBY A PORTION OF THE INTERLINER METAL UNMODIFIED BY DIFFUSION SEPARATES THE CLADDING METAL FROM THE BERYLLIUM-COPPER BASE. 